Warehouse Management In Microsoft Dynamics NAV 2013

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Warehouse Management inMicrosoft Dynamics NAV 2013Technical White Paper

Warehouse Management . 1Warehouse Overview . 2Basic or Advanced Warehousing . 3Warehouse Setup . 4Bin and Bin Content . 5Zone . 7Class . 7Location . 7First Expired First Out . 7Put-away Template . 7Inbound Warehouse Flow . 8Basic Warehousing . 9Advanced Warehousing . 10Internal Warehouse Flows . 12Internal Flows in Basic Warehousing . 12Internal Flows in Advanced Warehousing . 13Flushing Production Components in the Warehouse . 14Availability in the Warehouse . 16Bin Content and Reservations . 16Quantity Available to Pick . 16Quantity Available to Reserve. 17Outbound Warehouse Flow . 19Basic Warehousing . 20Advanced Warehousing . 21Integration with Inventory . 24Physical Inventory . 24

WAREHOUSE MANAGEMENTThis documentation gives an overview of the concepts and principles that are used in the Warehouse Managementfeatures in Microsoft Dynamics NAV 2013. It explains the design behind central warehouse features and howwarehousing integrates with other supply chain features.To differentiate the different complexity levels of the warehousing, this documentation is divided into two generalgroups, Basic and Advanced Warehousing, indicated by section titles. This simple differentiation covers differentcomplexity levels as defined by product granules and location setup. For more information, see Warehouse Setup.IN THIS SECTIONWarehouse OverviewWarehouse SetupInbound Warehouse FlowInternal Warehouse FlowsAvailability in the WarehouseOutbound Warehouse FlowIntegration with InventoryWAREHOUSE MANAGEMENT IN MICROSOFT DYNAMICS NAV 20131

WAREHOUSE OVERVIEWTo support the physical handling of items on the zone and bin level, all information must be traced for each transactionor movement in the warehouse. This is managed in the Warehouse Entry table. Each transaction is stored in awarehouse register.Warehouse documents and a warehouse journal are used to register item movements in the warehouse. Every time thatan item in the warehouse is moved, received, put away, picked, shipped, or adjusted, warehouse entries are registered tostore the physical information about zone, bin, and quantity. For more information, see Inbound Warehouse Flow,Internal Warehouse Flows, and Outbound Warehouse Flow.The Bin Content table is used to handle all the different dimensions of the contents of a bin per item, such as unit ofmeasure, maximum quantity, and minimum quantity. The Bin Content table also contains flow fields to the warehouseentries, warehouse instructions, and warehouse journal lines, which ensures that the availability of an item per bin and abin for an item can be calculated quickly. For more information, see Availability in the Warehouse.When item postings occur outside the warehouse module, a default adjustment bin per location is used to synchronizewarehouse entries with inventory entries. During physical inventory of the warehouse, any differences between thecalculated and counted quantities are recorded in the adjustment bin and then posted as correcting item ledger entries.For more information, see Integration with Inventory.The following illustration outlines typical warehouse flows.WAREHOUSE MANAGEMENT IN MICROSOFT DYNAMICS NAV 20132

BASIC OR ADVANCED WAREHOUSINGWarehouse functionality in Microsoft Dynamics NAV can be implemented in different complexity levels, depending on acompany’s processes and order volume. The main difference is that activities are performed order-by-order in basicwarehousing when they are consolidated for multiple orders in advanced warehousing.To differentiate between the different complexity levels, this documentation refers to two general denominations, Basicand Advanced Warehousing. This simple differentiation covers several different complexity levels as defined by productgranules and location setup, each supported by different UI documents. For more information, see Warehouse Setup.Note The most advanced level of warehousing is referred to as “WMS installations” in this documentation,since this level requires the most advanced granule, Warehouse Management Systems.The following different UI documents are used in basic and advanced warehousing.BASIC UI DOCUMENTS Inventory Put-awayInventory PickInventory MovementItem JournalItem Reclassification Journal(Various reports)ADVANCED UI DOCUMENTS Warehouse ReceiptPut-away WorksheetWarehouse Put-awayPick WorksheetWarehouse PickMovement WorksheetWarehouse MovementInternal Whse. PickInternal Whse. Put-awayBin Creation WorksheetBin Content Creation WorksheetWhse. Item JournalWhse. Item Reclass. Journal(Various reports)For more information about each document, see the respective window topics.TERMINOLOGYTo align with the financial concepts of purchases and sales, Microsoft Dynamics NAV warehouse documentation refers tothe following terms for item flow in the warehouse.TermDescriptionInbound flowItems moving into the warehouse location, such as purchases and inbound transfers.Internal flowItems moving inside the warehouse location, such as production components and output.Outbound flowItems moving out of the warehouse location, such as sales and outbound transfers.SEE ALSOWarehouse ManagementWAREHOUSE MANAGEMENT IN MICROSOFT DYNAMICS NAV 20133

WAREHOUSE SETUPWarehouse functionality in Microsoft Dynamics NAV 2013 contains different levels of complexity, as defined by licensepermissions in the offered granules. The level of complexity in a warehouse solution is largely defined by the bin setupon location cards, which in turn is license-controlled so that access to bin setup fields is defined by the license. Inaddition, the application objects in the license govern which UI document to use for the supported warehouse activities.The following warehouse-related granules exist: Basic Inventory (4010)Bin (4170)Put Away (4180)Warehouse Receipt (4190)Pick (4200)Warehouse Shipment (4210)Warehouse Management Systems (4620)Internal Picks and Put-aways (4630)Automated Data Capture System (4640)Bin Setup (4660)For more information about each granule, see “Microsoft Dynamics NAV Price List Explanation” in Microsoft DynamicsNAV Price Sheets (requires PartnerSource account),The following table shows which granules are required to define different warehouse complexity levels, which UIdocuments support each level, and which location codes reflect these levels in the CRONUS International Ltd.demonstration database.Complexity levelDescriptionUI documentCRONUS locationMinimum granulerequirement1No dedicated warehouseactivity.OrderBLUEBasic InventoryOrder, with bin codeSILVERBasic Inventory/BinInventory Putaway/InventoryMovement/Inventory Pick,with bin code(SILVER RequirePut-away orRequire Put-away)Basic se Putaway/WarehousePick/WarehouseShipment/Pick way/Pick/WarehouseShipmentReceive/ship posting fromorders.2No dedicated warehouseactivity.Receive/ship posting fromorders.Bin code is required.3Basic warehouse activity, orderby-order.Receive/ship posting frominventory put-away/pickdocuments.Bin code is required.4Advanced warehouse activity,for multiple orders.Consolidated receive/shipposting based on warehouseput-away/pick registrations.WAREHOUSE MANAGEMENT IN MICROSOFT DYNAMICS NAV 20134

Complexity levelDescriptionUI documentCRONUS locationMinimum granulerequirement5Advanced warehouse activity,for multiple orders.WarehouseReceipt/Warehouse eet/Put-awayWorksheet, with bin code(GREEN house ovement/PickWorksheet/Put-awayWorksheet/Internal Whse.Pick/Internal WarehousePut-away, withbin/class/zone codeWHITEBasic useShipment/WarehouseManagementSystems/Internal Picksand Put-aways/BinSetup/Automated DateCapture System/BinSetupConsolidated receive/shipposting based on warehouseput-away/pick registrations.Bin code is required.6NoteThis level isreferred toas “WMS”,since itrequires Advanced warehouse activity,for multiple orders.Consolidated receive/shipposting based on warehouseput-away/pick registrations.Bin code is required.Zone/class code is optional.Warehouse workers directed byworkflow.Bin replenishment planning.Bin ranking.Bin setup by capacity.Various worksheets for binmanagementADCS screensSlotting.Hand-help device integration.For examples of how the UI documents are used per warehouse complexity level, see Inbound Warehouse Flow andOutbound Warehouse Flow.BIN AND BIN CONTENTA bin is a storage device designed to contain discrete parts. It is the smallest container unit in Microsoft Dynamics NAV.Item quantities in bins are referred to as bin content. A lookup from the Item field or Bin Code field on any warehouserelated document line displays the calculated availability of the item in the bin.A bin content can be given a property of Fixed, Dedicated, or Default to define how the bin content can be used. Binswith none of these properties are referred to as floating bins.A fixed bin holds items that are assigned to the bin code in question. The Fixed bin property ensures that even if the bincontent is momentarily emptied, the bin content does not disappear, and the bin is therefore selected again as soon as ithas been replenished.A dedicated bin holds bin content that can only be picked for the dedicated resource, such as a machine center, thatuses the bin in question. Other non-pick content, such as quantities outbound on a shipment posting, can still beconsumed from a dedicated bin. Only bin content considered by the Create Pick algorithm is protected in a dedicatedbin.The Default bin property is used by the system to suggest bins for warehouse activities. At WMS locations, the Defaultbin property is not used. At locations where bins are required, the property is used in inbound flows to specify where toplace items. In outbound flows, the property is used to specify where to take items from.Note If the outbound items are placed in several bins, then items are first taken from the non-default bins, toempty that bin content, and then the remaining items are taken from the default bin.There can only be one default bin per item per location.WAREHOUSE MANAGEMENT IN MICROSOFT DYNAMICS NAV 20135

BIN TYPEIn WMS installations, you can restrict the warehouse activities that are allowed for a bin by assigning a bin type to it. Thefollowing bin types exist:Bin typeDescriptionRECEIVEItems posted as received but not yet put away.SHIPItems picked for warehouse shipment lines but not yet posted as shipped.PUT AWAYTypically, items to be stored in large units of measure but that you do not want to access for picking purposes.Because these bins are not used for picking, either for production orders or shipments, your use of a Put Away typebin might be limited, but this bin type could be useful if you have purchased a large quantity of items. Bins of this typeshould always have a low bin-ranking, so that when received items are put away, other higher-ranking PUTPICK binsfixed to the item are put away first. If you are using this type of bin, you must regularly perform bin replenishment sothat the items stored in these bins are also available in PUTPICK or PICK type bins.PICKItems to be used for picking only. The replenishment of these bins can only be made by movement, not by put-away.PUTPICKItems in bins that are suggested for both the put-away and pick functions. Bins of this type probably have different binrankings. You can set up your bulk storage bins as this type of bin with low bin rankings compared to your ordinarypick bins or forward picking area bins.QCThis bin is used for inventory adjustments if you specify this bin on the location card in the Adjustment Bin Code field.You can also set up bins of this type for defective items and items being inspected. You can move items to this type ofbin if you want to make them inaccessible to the usual item flow.NoteUnlike all other bin types, the QC bin type has none of the item handling check boxes selected by default.This indicates that any content you place in a QC bin is excluded from item flows.For all bin types, except PICK, PUTPICK, and PUTAWAY, no other activity is allowed for the bin than what is defined by itsbin type. For example, a bin of type Receive can only be used to receive items into or pick items from.NoteOnly movement can be made to bins of type RECEIVE and QC. Similarly, only movements can be made frombins of type SHIP and QC.BIN RANKINGIn advanced warehousing, you can automate and optimize how items are collected in put-away and pick worksheets byranking bins so that items are suggested taken or placed according to rank criteria to use warehouse space optimally.Put-away processes are optimized according to bin ranking by suggesting higher-ranking bins before lower-rankingbins. Similarly, pick processes are optimized by first suggesting items from bin content with high bin ranking.Furthermore, bin replenishments are suggested from lower-ranking bins to higher-ranking bins.Bin ranking together with bin content information are the basic properties that allow users to slot items in thewarehouse.BIN SETUPIn WMS installations, bins can be set up with capacity values, such as quantity, total cubage, and weight to control whichand how items are stored in the bin.On each item card, you can assign a unit of measure (UOM) for the item, such as pieces, pallets, liters, grams, or boxes.You can also have a base UOM for an item and specify larger UOMs that are based on it. For example, you can define apallet to equal 16 pieces, the latter being the base UOM.WAREHOUSE MANAGEMENT IN MICROSOFT DYNAMICS NAV 20136

If you want to set a maximum quantity of a specific item to be stored in an individual bin and the item has more thanone UOM, then you must set the maximum quantity for every UOM that exists on the item card. Accordingly, if an itemhas been set up to be handled in pieces and pallets, then the Max. Qty. field in the Bin Content window for that itemmust also be in pieces and pallets. Otherwise, the allowed quantity for that bin is not calculated correctly.Before you set capacity restrictions for bin contents on a bin, you must first make sure that the UOM and dimensions ofthe item have been set up on the item card.NoteIt is only possible to operate with multiple UOMs in WMS installations. I all other configurations, bin contentscan only be in the base UOM. In all transactions with a UOM higher than the item’s base UOM, the quantity isconverted to the base UOM.ZONEIn advanced warehousing, bins can be grouped in zones to manage how the workflow of warehouse activities isdirected.A zone could be a receiving zone or a stocking zone, and each zone can consist of one or several bins.Most properties assigned to a zone will by default be assigned to the bin that is created from that zone.CLASSIn advanced warehousing, you can assign warehouse class codes to items, bins, and zones to control where differentitem classes are stored, such as frozen goods. You can divide a zone into several warehouse classes. For example, itemsin the receiving zone can be stored as frozen, hazardous, or other class.When you work with warehouse classes and a default receiving/shipping bin, you must manually fill in the appropriatebins in the warehouse receipt and shipment lines.In inbound flows, the class code is only highlighted on inbound lines where the item class code does not match thedefault receiving bin. If the correct default bins are not assigned, then the quantity cannot be received.LOCATIONA location is a physical structure or place where inventory is received, stored, and shipped, potentially organized in bins.A location can be a warehouse, service car, showroom, plant, or an area in a plant.FIRST EXPIRED FIRST OUTIf you select the Pick According to FEFO check box on the Bin Policies FastTab on the location card, then item-trackeditems are picked according to their expiration date. The items with the earliest expiration dates are picked first.Warehouse activities in all pick and movement documents are sorted according to FEFO, unless the items in questionalready have serial/lot numbers assigned. If only a part of the quantity on the line already has serial/lot numbersassigned, then the remaining quantity to be picked is sorted according to FEFO.When picking by FEFO, the available items that expire first are gathered in a temporary item tracking list based on theexpiration date. If two items have the same expiration date, then the item with the lowest lot or serial number is pickedfirst. If the lot or serial numbers are the same, then the item that was registered first is selected first. Standard criteria forselecting items in pick bins, such as Bin Ranking and Break Bulk, are applied to this temporary FEFO item tracking list.PUT-AWAY TEMPLATEThe put-away template can be assigned to an item and to a location. The put-away template specifies a set of prioritizedrules that must be respected when creating put-aways. For example, a put-away template may require that the item isplaced in a bin with bin content that matches the UOM, and if a similar bin with enough capacity cannot be found, thenthe item must be placed in an empty bin.SEE ALSOWarehouse ManagementAvailability in the WarehouseWAREHOUSE MANAGEMENT IN MICROSOFT DYNAMICS NAV 20137

INBOUND WAREHOUSE FLOWThe inbound flow in a warehouse begins when items arrive in the warehouse of the company location, either receivedfrom external sources or from another company location. An employee registers the items, typically by scanning a barcode. From the receiving dock, warehouse activities are performed at different complexity levels to bring the items intothe storage area.Each item is identified and matched to a corresponding inbound source document. The following inbound sourcedocuments exist: Purchase orderInbound transfer orderSales return orderIn addition, the following internal source documents exist that function like inbound sources:1.Production order with output posting2.Assembly order with output postingThe last two represent inbound flows to the warehouse from internal operation areas. For more information aboutwarehouse handling for internal inbound and outbound processes, see Internal Warehouse Flows.Processes and UI documents in inbound warehouse flows are different for basic and advanced warehousing. The maindifference is that activities are performed order-by-order in basic warehousing, and they are consolidated for multipleorders in advanced warehousing. For more information about different warehouse complexity levels, see WarehouseOverview and Warehouse Setup.In Microsoft Dynamics NAV, the inbound processes of receiving and putting away can be performed in four ways usingdifferent functionalities depending on the warehouse complexity level.MethodInbound processBinsReceiptsAPost receipt and put-away from the order lineXBPost receipt and put-away from an inventoryput-away documentCPost receipt and put-away from a warehousereceipt documentXDPost receipt from a warehouse receiptdocument and post put-away from awarehouse put-away documentXPut-awaysComplexity level (SeeWarehouse Setup)2X34/5/6X4/5/6Selecting an approach depends on the company's accepted practices and the level of their organizational complexity. Inan order-by-order warehouse environment, where most of the warehouse staff works directly with order documents, acompany might decide to use method A. An order-by-order warehouse that has a more complex put-away process, orwhere there are dedicated warehouse staff to perform warehousing functions, might decide to separate their put-awayfunctions from the order document, method B. Additionally, companies that need to plan the handling of multipleorders may find it helpful to use warehouse receipt documents, methods C and D.In methods A, B, and C, the actions of receiving and putting away are combined in one step when posting thecorresponding documents as received. In method D, the receipt is posted first to recognize the increase of inventory andthat items are available for sale. The warehouse worker then registers the put-away to make items available to pick.WAREHOUSE MANAGEMENT IN MICROSOFT DYNAMICS NAV 20138

BASIC WAREHOUSINGThe following diagram illustrates the inbound warehouse flows by document type in basic warehousing. The numbers inthe diagram correspond with the steps in the sections following the diagram.1: RELEASE SOURCE DOCUMENT / CREATE INVENTORY PUT-AWAYWhen items are received in the warehouse, the user who is responsible for receiving releases the source document, suchas a purchase order or an inbound transfer order, to signal to warehouse workers that the received items can be putaway in inventory. Alternatively, the user creates inventory put-away documents for individual order lines, in a pushfashion, based on specified bins and quantities to handle.2: CREATE INBOUND REQUESTWhen the inbound source document is released, an inbound warehouse request is created automatically. It containsreferences to the source document type and number and is not visible to the user.3: CREATE INVENTORY PUT-AWAYIn the Inventory Put-away window, the warehouse worker retrieves, in a pull fashion, the pending source document linesbased on inbound warehouse requests. Alternatively, the inventory put-away lines are already created, in a push fashion,by the user who is responsible for the source document.4: POST INVENTORY PUT-AWAYOn each line for items that have been put away, partially or fully, the warehouse worker fills in the Quantity field, andthen posts the inventory put-away. Source documents that are related to the inventory put-away are posted as received.Positive item ledger entries are created, warehouse entries are created, and the put-away request is deleted, if fullyhandled. For example, the Quantity Received field on the inbound source document line is updated. A posted receiptdocument is created that reflects the purchase order, for example, and the received items.WAREHOUSE MANAGEMENT IN MICROSOFT DYNAMICS NAV 20139

ADVANCED WAREHOUSINGThe following diagram illustrates the inbound warehouse flow by document type in advanced warehousing. Thenumbers in the diagram correspond with the steps in the sections following the diagram.1: RELEASE SOURCE DOCUMENTWhen items are received in the warehouse, the user who is responsible for receiving releases the source document, suchas a purchase order or an inbound transfer order, to signal to warehouse workers that the received items can be putaway in inventory.2: CREATE INBOUND REQUESTWhen the inbound source document is released, an inbound warehouse request is created automatically. It containsreferences to the source document type and number and is not visible to the user.3: CREATE WAREHOUSE RECEIPTIn the Warehouse Receipt window, the user who is responsible for receiving items retrieves the pending sourcedocument lines based on the inbound warehouse request. Several source document lines can be combined in onewarehouse receipt document.The user fills in the Qty. to Handle field and selects the receiving zone and bin, if required.WAREHOUSE MANAGEMENT IN MICROSOFT DYNAMICS NAV 201310

4: POST WAREHOUSE RECEIPTThe user posts the warehouse receipt. Positive item ledger entries are created. For example, the Quantity Received fieldon the inbound source document line is updated.5: CREATE WAREHOUSE INTERNAL PUT-AWAYThe user who is responsible for putting away from internal operations creates a warehouse internal put-away for itemsthat have to be put away in the warehouse, such as production or assembly output. The user specifies quantity, zone,and bin from where the items should be put away, potentially with the Get Bin Content function. The user releases thewarehouse internal put-away, which creates an inbound warehouse request so that the task can be retrieved inwarehouse put-away documents or in the put-away worksheet.6: CREATE PUT-AWAY REQUESTWhen the inbound source document is posted, a warehouse put-away request is created automatically. It containsreferences to the source document type and number and is not visible to the user. Depending on the setup, output froma production order also creates a put-away request to put the finished items away in inventory.7: GENERATE PUT-AWAY WORKSHEET LINES (OPTIONAL)The user who is responsible for coordinating put-aways retrieves warehouse put-away lines in the Put-away Worksheetbased on posted warehouse receipts or internal operations with output. The user selects the lines to be put-away andprepares the put-aways by specifying which bins to take from, which bins to place in, and how many units to handle. Thebins may be predefined by the setup of the warehouse location or operation resource.When all put-aways are planned and assigned to warehouse workers, the user generates the warehouse put-awaydocuments. Fully assigned put-aways lines are deleted from the Put-away Worksheet.NoteIf the Use Put-away Work

warehousing integrates with other supply chain features. To differentiate the different complexity levels of the warehousing, this documentation is divided into two general groups, Basic and Advanced Warehousing, indicated by sec

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